Remote control assembly having universal components

ABSTRACT

A method of fabricating a remote control assembly having a conduit (12) movably supporting a core element (14) with an end fitting (16) disposed on the conduit (12) for mechanical engagement with a ferrule (18) and a slug (20) disposed on the core element (14). The method comprises the steps of selecting a ferrule (18) for supporting the conduit (12) on a support structure (22) from a plurality of ferrule (18) configurations and snapping the ferrule (18) into mechanical connection with the end fitting (16) while inserting the core element (14) through the conduit (12) and ferrule (18). A terminal member (38, 138, 238), having a slug pocket (40) therein and a connector for connection to a control member, is selected from a plurality of terminal member (38, 138, 238) configurations and it is placed on the core element (14) with the slug (20) in the slug pocket (40). A collar (42) is placed over the slug pocket (40) as the collar (42) is mechanically connected to the terminal member (38, 138, 238) to cover the slug pocket (40) and retain the slug (20) in the slug pocket (40). The selection may be of a ferrule (18) having a first outside guide tube (28) and a collar (42) having a first inside guide tube (48) for telescoping relationship with the first outside guide tube (28) or, sequentially may be of a collar (42) with a second outside guide tube (50) and placing a second inside guide tube (52) to extend from the end fitting (16) for telescoping relationship with the second outside guide tube (50).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention relates to a motion transmitting remote controlassembly of the type for transmitting motion in a curved path by aflexible motion transmitting core element movably supported in a conduitwhich is supported by a support structure.

2. Description of the Prior Art

Such remote control assemblies are widely used in the automotiveindustry for accelerators, vents, mirrors, hoods, cruise controls, etc.typically each control assembly is manufactured for a dedicated purposeand is only suitable for that dedicated installation. This requires theshipment and inventory of a large number of large and varied assemblies.There is a need, therefore, to standardize such control assemblies.

SUMMARY OF THE INVENTION AND ADVANTAGES

The invention provides a method of fabricating a remote control assemblyhaving a conduit movably supporting a core element with an end fittingdisposed on the conduit for mechanical engagement with a ferrule and aslug disposed on the core element. The method comprises the steps of:selecting a ferrule for supporting the conduit on a support structurefrom a plurality of ferrule configurations and mechanically connectingthe ferrule to the end fitting with a core element inserted through theconduit and ferrule. Also included is the step of selecting a terminalmember having a slug pocket therein and a connector for connection to acontrol member from a plurality of terminal member configurations andplacing the terminal member on the core element with the slug in theslug pocket.

The method, therefore, provides such an assembly wherein the ferrule ismechanically connected to the end fitting and is adapted for attachmentto a support structure, the terminal member has a slug pocket and isadapted for connection to a control member, and the slug is connected tothe core element and is disposed in the slug pocket of the terminalmember whereby the ferrule may be selected from a plurality of ferruleseach having a different configuration and the terminal member beselected from a plurality of terminal members each having a differentconfiguration.

Accordingly, various combinations of remote control assemblies may befabricated from a standardized or universal conduit and end fitting byselecting from various components thereby reducing the need for a widevariety of total remote control assemblies including dedicated conduitsand end fittings to satisfy a wide variety of environments.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a side elevational view of a first combination of components;

FIG. 2 is a side elevational view of a second combination of components;

FIG. 3 is a side elevational view of a third combination of components;

FIG. 4 is a cross sectional view of the combination of FIG. 1 in thefully assembled condition;

FIG. 5 is a cross sectional view of the combination of FIG. 2 in thefully assembled condition; and

FIG. 6 is a cross sectional view of the combination of FIG. 3 in thefully assembled condition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views, a method offabricating a remote control assembly is illustrated. The remote controlassembly includes a conduit 12 for movably supporting a core element 14.A universal end fitting 16 is disposed on the conduit 12 for mechanicalengagement with a ferrule 18 and a slug 20 is disposed on the coreelement 14. The core element 14 is made of metal wire or metal filamentsstranded together. The conduit 12 is of the well type comprising aninner liner of organic polymeric material surrounded by a wire orfilaments disposed on a long helical lead and surrounded by a casing oforganic polymeric material.

The method of fabricating the remote control assembly includes the stepof selecting a ferrule 18 for supporting the conduit 12 on a supportstructure 22 from a plurality of ferrule 18 configurations. The ferrule18 body is the same in all configurations by including a cylindricalportion molded of organic polymeric material so as to be diffused withthe organic polymeric material of the conduit 12 and expanding into aflange 24 for engaging one side of the support structure 22 about anaperture therein and a pair of cantilevered tabs 26 for engaging theopposite side of the support structure 22 about the aperture therein.This is the totality of the ferrule 18 used in the combination of FIGS.2 and 5; however, the ferrule 18 of FIGS. 1 and 4 includes an outsideguide tube 28 formed integrally therewith and extending along thelongitudinal axis, and the ferrule 18 of FIGS. 3 and 6 includes aprojection 30 upon which is snapped a wiper 32. The wiper 32 slidablyengages the core element to keep water and other contaminants out of theassembly.

The exterior of the end fitting 16 and the interior of the cylindricalportion of the ferrule 18 include a tongue and groove connection betweenthe ferrule 18 and end fitting 16 for mechanically connecting theferrule 18 to the end fitting 16 whereby the ferrule 18 may rotate aboutthe longitudinal axis of the of the conduit 12 relative to the fitting16. The end fitting 16 presents a groove 34 into which is snapped atongue 36 which extends inwardly from the interior of the cylindricalportion of the ferrule 18. Upon selection of the ferrule 18, the nextstep is to mechanically connect the ferrule 18 to the end fitting 16 bysnapping the tongue 36 into the groove 34. The mechanical connection istherefore further defined as rotatably connecting the ferrule 18 to theend fitting 16 so that the ferrule 18 is free to rotate about thelongitudinal axis of the conduit 12 relative to the end fitting 16. Thecore element 14 is inserted through the conduit 12 and the ferrule 18.

The method includes the step of selecting a terminal member from aplurality of terminal member configurations. The first terminal memberconfiguration is shown at 38 in FIGS. 1 and 4, a second at 138 in FIGS.2 and 5, and a third at 238 in FIGS. 3 and 6. Each terminal member 38,138, 238 presents a slug pocket 40 therein for receiving the slug 20with the core element 14 extending through a slot in the end wall of theslug pocket 40. Thus, the terminal member 38, 138, 238 is placed on thecore element 14 by inserting the core element 14 into the slot as theslug 20 is deposited in the slug pocket 40. Each terminal member 38,138, 238 also has a connector for connection to a control member;however, this connector is selected from a plurality of differentconfigurations. Any one of the terminal members 38, 138, 238 may haveeither a connector presenting a pocket for receiving a nail head shapedcontrol member, as shown in terminal members 38 and 238 or a connectorpresenting a pocket for receiving a ball shaped control member, as shownin the terminal member 138. Therefore, the selection of the terminalmember 38, 138, 238 is further defined as further defined as selecting aterminal member 38, 238 having a connector for connection to a nail headshaped control member and sequentially selecting a terminal member 138having a ball shaped control member.

The method also includes the step of placing a collar 42 over the slugpocket 40 and mechanically connecting the collar 42 to the terminalmember 38, 138, 238 to cover the slug pocket 40 and retain the slug 20in the slug pocket 40. The terminal member 38, 138, 238 presentsprojections 44 which snap into holes 46 in the collar 42 formechanically connecting the collar 42 to the terminal member 38, 138,238. The collar 42 is selected from a plurality of differentconfigurations. The configuration of FIGS. 1 and 4 includes an insideguide tube 48 formed integrally therewith, whereas the collar 42 ofFIGS. 2 and 5 includes an outside guide tube 50 formed integrallytherewith, and the collar 42 of FIGS. 3 and 6 has no such tubularextension. In the combination of FIGS. 2 and 5, an inside guide tube 52is inserted into a counterbore 54 in the end fitting 16 with one end ofthe inside guide tube retained in the counterbore and extending from theend fitting 16 for telescoping relationship with the outside guide tube50. The inside guide tube 52 may be press fit or adhesively secured inthe counterbore.

Accordingly, the selecting is further defined as selecting a firstcombination including a ferrule 18 having a first outside guide tube 28and a collar 42 having a first inside guide tube 48 for telescopingrelationship with the first outside guide tube 28 sequentially withselecting a second combination including a collar 42 with a secondoutside guide tube 50 and placing a second inside guide tube 52 toextend from the end fitting 16 for telescoping relationship with thesecond outside guide tube 50. The selection will depend upon whether therouting is upward, whereupon the combination of FIGS. 2 and 5 will beselected to keep water out of the assembly, or downward, whereupon thecombination of FIGS. 1 and 4 will be selected. The combination of FIGS.3 and 6 could be used in various orientations. The method also includesthe step of placing a spring between the collar 42 and the ferrule 18 tourge the telescoping relationship therebetween in the extendingdirection. More specifically, in the combination of FIGS. 1 and 4, thespring 56 is coiled about the inside guide tube 48 between the end ofthe outside guide tube 28 and the collar 42 whereas the spring 58 in thecombination of FIGS. 2 and 5 is coiled about the inside guide tube 52between the ferrule 18 and the outside guide tube 50. The springs 56 and58 urge the telescoping relationship between the outside 28 and 50 andinside guide tubes 48 and 52 in the extending direction, i.e., toincrease the overall combined length.

Accordingly, during the assembly or fabrication process, variouscombinations may be selected; the combination may be one where theoutside guide tube 28 extends from the ferrule 18 or the inside guidetube 52 extends from the ferrule 18 as it is supported by the endfitting 16. Furthermore, the terminal member 38, 138, 238 may, withinthe above varied combinations, also vary between a nail head pocket or aball pocket, and with different distances between the pocket and thecollar 42, as is clear by comparing FIGS. 1 and 2.

The invention, therefore, provides a motion transmitting remoter controlassembly comprising a conduit 12 having first and second ends with auniversal end fitting 16 disposed on the first end of the conduit 12 andthe core element 14 is movably supported in the conduit 12 and extendsfrom the first and second ends of the conduit 12. The ferrule 18 ismechanically connected to the end fitting 16 and is adapted forattachment to a support structure 22. More specifically, a tongue 36 andgroove 34 connection is disposed between the ferrule 18 and the endfitting 16 for rotatably connecting the ferrule 18 to the end fitting 16whereby the ferrule 18 may rotate about the longitudinal axis of theconduit 12 relative to the end fitting 16. The terminal member 38, 138,238 has a slug pocket 40 and is adapted for connection to a controlmember and the slug 20 is connected to the core element 14 and isdisposed in the slug pocket 40 of the terminal member 38, 138, 238whereby the ferrule 18 may be selected from a plurality of ferrules 18each having a different configuration and the terminal member 38, 138,238 may be selected from a plurality of terminal members 38, 138, 238each having a different configuration. The ferrule 18 includes a flange24 for engaging one side of a support structure 22 about an aperturetherein and a pair of flexible tabs 26 for engaging the opposite side ofthe support structure 22 about the aperture therein. The body of theferrule 18 may be round to engage a circular aperture or rectangular toengage a four sided aperture.

The collar 42 is mechanically connected to the terminal member 38, 138,238 and is disposed over the slug pocket 40 to retain the slug 20 in theslug pocket 40. The outside guide tube 28 and 50 extends from one of theferrule 18 and the collar 42 and an inside guide tube extends from oneof the end fitting 16 and the collar 42 for telescoping relationship ofthe tubes. The spring is disposed between the collar 42 and the ferrule18 to urge the telescoping relationship in the extending direction.

As alluded to above, the end fitting 16 includes a counterbore and theinside guide tube 52 is retained in the counterbore and extendstherefrom, the outside tube 50 extending from the collar 42 and in thetelescoping relationship with the inside tube 52. Also as alluded toabove, the terminal member 38, 138, 238 has a connector for receivingone of a nail shaped control member and a ball shaped control member.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology which has been used is intended to bein the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. It is, therefore, to beunderstood that within the scope of the appended claims, whereinreference numerals are merely for convenience and are not to be in anyway limiting, the invention may be practiced otherwise than asspecifically described.

What is claimed is:
 1. A motion transmitting remote control assembly comprising:a conduit (12) having first and second ends; an end fitting (16) disposed on said first end of said conduit (12); a core element (14) movably supported in said conduit (12) and extending from said first and second ends of said conduit (12); a ferrule (18) mechanically connected to said end fitting (16) and adapted for attachment to a support structure (22); said end fitting (16) being disposed between and interconnecting said conduit (12) and said ferrule (18), a terminal member (38, 138, 238) having a slug pocket (40) and adapted for connection to a control member; and a slug (20) connected to said core element (14) and disposed in said slug pocket (40) of said terminal member (38, 138, 238) whereby said ferrule (18) may be selected from a plurality of ferrules (18) each having a different configuration and said terminal member (38, 138, 238) may be selected from a plurality of terminal members (38, 138, 238) each having a different configuration.
 2. An assembly as set forth in claim 1 wherein said terminal member (38, 138, 238) having a connector for receiving one of a nail shaped control member and a ball shaped control member.
 3. An assembly as set forth in claim 1 wherein said ferrule (18) includes a flange (24) for engaging one side of a support structure (22) about an aperture therein and a pair of flexible tabs (26) for engaging the opposite side of the support structure (22) about the aperture therein.
 4. An assembly as set forth in claim 1 including a core element wiper (32) on said ferrule (18) for slidably engaging said core element (14).
 5. An assembly as set forth in claim 1 including a tongue (36) and groove (34) connection between said ferrule (18) and said end fitting (16) for mechanically connecting said ferrule (18) to said end fitting (16).
 6. An assembly as set forth in claim 5 wherein said tongue (36) and groove (34) connection rotatably connects said ferrule (18) to said end fitting (16) whereby said ferrule (18) may rotate about the longitudinal axis of said conduit (12) relative to said end fitting (16).
 7. An assembly as set forth in claim 1 including a collar (42) mechanically connected to said terminal member (38, 138, 238) and disposed over said slug pocket (40) to retain said slug (20) in said slug pocket (40).
 8. An assembly as set forth in claim 7 including an outside guide tube extending from one of said ferrule (18) and said collar (42) and an inside guide tube extending from one of said end fitting (16) and said collar (42) for telescoping relationship of said tubes.
 9. An assembly as set forth in claim 8 including a spring disposed between said collar (42) and said ferrule (18) to urge the telescoping relationship in the extending direction.
 10. An assembly as set forth in claim 8 wherein said end fitting (16) includes a counterbore and said inside tube (52) is retained in said counterbore and extends therefrom, said outside tube (50) extending from said collar (42) and in said telescoping relationship with said inside tube (52). 